Artificial intelligence in the post-deep learning era
Mukesh kumar training report
1. 1
VIIITH
SEMESTER INDUSTRIALTRAINING
REPORT
COMPLETED AT :-
BHARAT WAGAON & ENGINEERING CO. LTD. (BWEL) ,
MUZAFFARPUR UNIT
( A Govt. of India Undertaking – Ministry of Railways)
FROM :- 5TH
OF FEBRUARY TO 28TH
OF MAY
SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
NAME :- MUKESH KUMAR
REG. NO. :- 1079175467
ROLL NO. :- 49
SESSION :- 2010-2014
DEPARTMENT OF MECHANICAL ENGINEERING
Delhi Institute of Technology Management & Research, Faridabad
MDU, ROHTAK
2. 2
DELHI INSTITUTE OF TECHNOLOGY, MANAGEMENT
& RESEARCH, FARIDABAD
SUBMITTED BY:-
MUKESH KUMAR
MECHANICAL ENGG. VIIITH
SEM
REG. NO. – 1079175467
ROLL NO. - 49
BATCH - 2010-2014
SUBMITTED TO:-
Mr. PAWAN TANEJA
H.O.D.- MECHANICAL ENGINEERING
3. 3
SUMMARY OR ABSTRACT OF THE REPORT:-
The relationship between land and labour is nearly as old as human existence on the earth. As we
cannot imagine the process of creation of wealth without labour, it is treated as more important.
The satisfaction of worker is linked with the question of our existence & profitability. Increase in
production is not possible without the fullest co-operation between management and labour and
the most important determinant is a manager’s ability to minimize the conflicts and maximize the
satisfaction of employers & employees. This situation may be created by taking intense are upon
labour productivity, which is based on incentives, motivation compensation have been evolved
over a period of time. More particularly with a view to motivate the worker & employee
concerned.
The success of any organisation also depends upon the facts that effectively and efficiently the
wage and salary administration is handled by the manager, that can turn the worker towards
satisfaction level. If an ideal match between technical innovations and worker’s aspiration have
been set-up, they may be capable of producing new idea developing and improving capital goods
and modifying the available physical and financial resource in order to achieve greater
productivity, satisfaction depends on the strategies adopted for wage and salary administration.
By observing the above points, it can easily be concluded that the importance of wage and salary
administration at present day cannot be ignored. While working on this topic, my present aim is
to evaluate the wage and salary administration in company like BWEL, Muzaffarpur unit,
Muzaffarpur. I have also evaluated the various methods of wages and salary administration.
Thus progress is a continuous process. It is relative and absolute. We cannot stop at a certain
destination and declare that target has been achieved and we need to go further. One has rightly
said the following lines :-
“The woods are lovely dark and deep, but I have promises to keep a mile to go before I sleeps.”
Summer Training Programmes are designed to give the future feel of the corporate happening
and work culture. These real life situations are entirely different from the simulated exercise
enacted in an artificial environment inside reason that the summer training programmes are
designed so that the managers of tomorrow may not feel ill in case when the times come to
shoulder responsibility.
That experience that I have gathered over the last sixteen weeks have certainly provided me with
orientation which I believe will help me to shoulder any assignment, successfully in near future.
I have tried my level best to arrange the work in a systematic and chronological manner.
4. 4
We read theoretically the matters noted in the books but are not very much acquainted with the
actual working in the organisation. There becomes a lot of difference between the bookish
knowledge & the practical Knowledge. To have a practical feelings & go through the working an
organisation is very much beneficial for us. The experience gain during these sixteen weeks is of
highly importance.
Even though this project report will be helpful for the management of BWEL, to look back at
their role and procedures regarding wages and salary activity stake necessary steps to improve it.
The future students of management disciplines who want to know abut the working of BWEL,
Muzaffarpur, especially with regard to wage & salary will get a massive help from this project
report.
5. 5
ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been possible without the kind
support and help of many individuals and organizations. I would like to extend my sincere thanks
to all of them.
I am highly indebted to Mr. V.K. Shrivastava for their guidance and constant supervision as
well as for providing necessary information regarding the project & also for their support in
completing the project.
I would like to express my gratitude towards my parents & member of Bharat Wagon &
Engineering Com. Ltd. (BWEL) Muzaffarpur Unit, for their kind co-operation and
encouragement which help me in completion of this project.
I would like to express my special gratitude and thanks to industry persons for giving me such
attention and time.
My thanks and appreciations also go to my colleague in developing the project and people who
have willingly helped me out with their abilities.
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CONTENTS
SUMMARY OR ABSTRRACT OF THE REPORT.................................................03
ACKNOWLEDGEMENT.........................................................................................05
COMPANY PROFILE..............................................................................................10
ABOUT BHARAT WAGON....................................................................................11
HISTORICAL BACKGROUND..............................................................................12
REHABILATION OF WAGON...............................................................................16
SELLING WITH INDIAN RAILWAY....................................................................18
MARKETING OF RAW MATERIAL.....................................................................22
ORGANISATIONAL STRUCTURE.......................................................................24
PRESS & SMITHY SHOP........................................................................................44
CUTTING & WELDING SHOP...............................................................................48
DRILLING SHOP.....................................................................................................52
MACHINE SHOP.....................................................................................................54
FOUNDRY SHOP....................................................................................................58
WAGON ASSEMBLY SHOP..................................................................................61
FINISHING SHOP....................................................................................................63
TEMPLATE SHOP....................................................................................................65
SCRAP MEANING & DDEFINATION……...........................................................66
LIST OF SCRAP MATERIALS PRODUCED IN BWEL MUZAFFARPUR.........68
SCRAP MANAGEMENT AND IMPORTANCE.....................................................71
VARIOUS LOCATIONS FOR SCRAP IN SCRAP DEPOT....................................73
TERMS AND CONDITIONS OF AUCTIONS SALE OF SCRAP BWEL MZFF...74
SCRAP MANAGEMENT SYSTEM (SMS)...............................................................78
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COMPANY PROFILE
Bharat Wagon is an engineering Industry commanding very good reputation and having decades
of experience with two manufacturing units in Mokama & Muzaffarpur in the state of Bihar.
Our both units have been accredited with ISO-9001:2000 Quality management System
Standards for manufacturing of wagons. The product profile of Bharat Wagons and the enriched
experience reveal the credibility of our company and the capability of our skilled personnel that
have brought laurels to the organization.
BWEL manufacturers railway wagons, sugar mill machineries & fabrications castings and
miscellaneous project equipment. Railway wagons comprise the bulk of the turnover of the
company. The company has a wagon manufacturing capacity of 2500 FWU p.a. Railway
wagons are produced at the Mokamah and Muzaffarpur units.
The wagons are catered to the Indian Railways and Ministry of Defence. Some special
purpose wagons are also produced according to specific customer requirements. The unit at
Mokamah s capable of producing only board gauge units while the unit at Muzaffarpur is
equipped to produce both Broad gauge and Metre gauge units. In addition to railway wagons
the units are capable of producing all relevant wagon components. BWEL diversified into
turnkey project o 1979 as part of its diversification strategy and a separate Project
Division was set up in 1995. This division has successfully executed a number of turnkey
projects.
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ABOUT BHARAT WAGON
Bharat Wagon & Engineering Company Limited (“BWEL” or “the Company”) is a subsidiary
of Bharat Bhari Udyog Nigam Limited (BBUNL) and is engaged in the manufacture of Railway
Wagons, Sugar Mill Machines & Steel Fabrications and Project Equipment. The entire equity
component of BWEL is held by BBUNL and the company is under the administrative control of
the Department of Heavy Industries (DHI).
BUNL in consonance with DHI has decided to disinvest up to 74% or 100% of its holding in
BWEL in favour of a strategic/joint venture who would provide technological inputs, marketing
support, managerial skills and fresh funds and such other assistance to BWEL as may be
required to ensure healthy and consistent financial performance. This would complement the
existing strengths of WHEL in possessing a team of skilled and highly experienced personnel
and a well-respected brand among wagon manufacturers in the country.
The administrative control of M/s BWEL was incorporated in 1978, by an Act of Parliament,
through the nationalization and subsequent amalgamation of two erstwhile companies. Arthur
Butler & Co. located at Muzaffarpur and Britannia Engineering Works located at
Mokamah. The decision of the Government was driven by the industrial sickness in both the
companies, which had forced the government to take over their management. Subsequently, in
1983 a third unit was added at Industrial Estate (Bela) Muzaffarpur for manufacturing LPG
cylinders. In 1986, BWEL was made a wholly owned subsidiary of Bharat Bhari Udyog Nigam
(BBUNL) which is the holding company for 9 nationalized companies in the heavy engineering
sector and comes under the auspicec of the Ministry of Heavy Industries.
BWEL is headquartered at Patna and has two regional offices in Delhi and Kolkata. The
company has manufacturing unit at Mokamah, Bela and Muzaffarpur. The company is primarily
engaged in the manufacturing of Railway Wagons. As a diversification measure the company
has also entered into Steel Structures. Bridge Fabrications, Oil Tanks, Sugar Mill Equipment,
Canal Gates and other Misc, Project Equipment.
The Units at Mokamah and Muzaffarpur have received the ISO-9002 certification for wagon
manufacturing. The company has achieved a number of distinctions in the area of productivity
including the Indira Gandhi Memorial Award for Productivity in 1988, Rajeev Gandhi
Memorial National Award for productivity in 1990 and National Produtivity Councial
Certificate of Merit in 1993.
Bharat Wagon & Engg. Co. Ltd. (BWEL), Patna, a central PSE and subsidiary of Bharat Bhari
Udyog Nigam Ltd. (BBUNL) is transferres from the Department of Heavy Industry, Ministry of
Heavy Industries and Public Enterprises to the Ministry of Railway w.e.f. 13th
August, 2008
(AN).
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Bharat Wagon & Engineering Company Ltd. (BWEL), was incorporated on 8th
December 1978
as a Public Sector Unit by take over of two historical wagon manufacturing units of Arther
Butler & Co and Britannia Engineering Co, both in Bihar at Muzaffarpur and Mokamah. The
third industrial unit was added to the company in 1983-84 at Bela, Muzaffarpur for manufacture
of LPG Cylinders. In the year 1986 the company become a subsidiary of BBUNL, Calcutta.
Corporate/Head Office –
Bharat Wagon & Engg. Co. Ltd.,
‘C’ Block, 5th
Floor,
Mauryalok Complex,
Dak Bungalow Road,
Patna – 800001
Regional Offices :
1. Bharat Wagon & Engg. Co. Ltd.,
26 A, Barakhamba Road
New Delhi – 110001
2. Bharat Wagon & Engg. Co. Ltd.,
C/O Burn Standard Co. Ltd.,
40, Strand Road,
104, Akashdeep Building,
4th
Floor, Room No. – 12,
Kolkata – 700001
Factories/Works :
1.Bharat Wagon & Engg. Co. Ltd.,
Muzaffarpur Unit,
Muzaffarpur – 842001
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HISTORICAL BACKGROUND
M/S BHARAT WAGON & ENGINEERING COMPANY LIMITED is a Government of India
undertaking under the ministry of Heavy Industry Department of bureau of public Enterprises,
Govt. of India. The Govt. of India undertaking was incorporated under the company act, 1956 on
the 4th
day of December, 1978 with an authorized capital of rupees five crores. Bharat Wagon
and Engineering Company Limited comes into being in terms of the Britannia Engineering
Company Limited (Mokama unit) and Arthur Butler and Company Limited (Muzaffarpur) under
the acquisition and transfer of undertaking of Britannia Engineering Company Limited. Mokama
unit & Arthur Butler & Company Limited (Muzaffarpur) with retrospective effect from 1st
of
April, 1978.
The Britannia Engineering Company Limited Was incorporated in 1917 with its registered office
at Calcutta. It owned an engineering unit at Titagarh (where it manufactured road rollers. Jute
mills machinery unit and other industrial unit) & also a steel foundation at Titagarh and third unit
, which was set in 1960 at Mokama to manufacture railway wagons. The engineering unit at
Titagarh closed down in 1970 and on 22nd
may, 1976 its management was taken over by the
Central Government & interested to M/S Westing House Farmers Limited, Calcutta, a company
being managed by the Government has taken complete financial and managerial responsibilities
for managing the Titagarh unit. The Wagon unit at Mokama closed down in March 1973. The
Central Government took over its management on 10th
February 1974 under the Industrial
Development and Regulation Act and the unit was reopened on 22nd
of February 1974. When it
was closed down in March 1973 it employed 888 persons.
This labor was confirmed to then industrial establishment located in North East region of India.
It was not like a modern industry as we see understanding about a unit today. It was indigo
industry based on agricultural product, which intricate blue colour, a product of indigo
cultivation by means of smaller plants. In 2nd
district gazetteer of Muzaffarpur district 1958,
Much encouraged by the remunerative aspect Mr. Arthur also thought to have his permanent
establishment somewhere. The first did setup small shop that sheds with smithy devices
something at samastipur, then a central place of communication during those days and then
enthusiast Mr. Butler also joined him and began working as two friends doing the same business.
They could pull their resources and began working as partners in course of time, their work
expanded and the place proved in sufficient to the requirement. They moved their place of
business from samastipur to Muzaffarpur (a place situated in 27’7’ North latitude and 85’24 East
longitude is in the central place of north Bihar) a few yards away from present location of the
factory. They began doing bigger volume of business and the smaller firms fasts developed into
shed. They went yards away from present location of the factory. They began doing bigger
14. 14
volume of business and the smaller firms fasts developed into bigger shed. They went on adding
to their small unit, different sections and then their industrial venture took a factory form.
Mr.L.S.S.O.Malley I.C.S. mentioned in the first district gazetteer of Muzaffarpur district (1907)
M/s Arthur Butler Company as only engineering workshop registered under the factories act
having 107 employees on hand already started its industrial activities as the only modern
industrial world.
Mr. P.C. Roy writes in the 2nd
district gazetteer of Muzaffarpur district (1958) that in the last
quarter of the 19th
century, the development of the artificial days, which freely imported from
abroad, affected the prospect of the indigo industry severally sit lost the ground. But the Arthur
Butler venture being in the form of the factory followed. Other industries. One more advantage
was with them that they were English people and every industrial activities was being owned and
managed by the English people themselves.
Arthur Butler started a new line of business of making screw piles having steel as superstructures
there on which could be easily installed, dismantled and shifted was the course changed given by
1910. It expanded as bigger partnership concern.
By 1919, it was registered under joint stock Company Act as a company and also fixed up its
workshop at the present site of the factory just adjacent to Muzaffarpur Railway station. Arthur
Butler and Company has been also famous for civil works and they were experts in designing
screw piles all the fabricated steel bridge in Northern India stand over today as a symbol.
By 1925 when most of the factories used to import machines from England even minor parts of
the sugar industries, the efforts of Arthur butler where credit worth of the management
development production from repair side of business
It was the year 1938 in which it used to pay heavy dividend to its shareholders. During the 2nd
world war it expanded so much so that it could acquire a plant of its own which was used by Mr.
H.M. Wealthevall. It also expanded its employment roughly about one thousand persons.
Managing agents changed after 1943, from Balmer Lawrie Co.Ltd. to purchase the company.
The English shareholder sold their shares and virtually repatriated from India. The Bihar Motor
Service section was also closed and new line of repaint. Railway goods wagon and managing
agent.
The Bharat Brothers controlled the management, however, till act for 1954, the management
changed hands and Kakrania and sonthalli as purchase the shares and owned the company only
small part of the share of the company were in the market and it was easy for them to sell off the
ownership. The two groups formed a managing system which was obliged by virtue of
amendments to the India Companies Act, 1968. Since them it began to be managed by a Board
of 4 Directors consisting of always the family namely Kakranias and Sonthallias.
15. 15
During this period the Government decided to stop import of railway goods Wagons and this
gave big impetus to Indian factories to develop wagon building. Arthur Butler Company being
ideally situated on the meter gauge railways head at Muzaffarpur and doing the repairing
railways.
Work till 1954 took advantage of the opportunity and it did expand its workshop to take up the
new railway job. In course of time they brought suitable new machines and arranged to build all
types of railway wagons.
During the peak period, 1960-1965, it employed even about 1300 persons. In 1967 when the
company faced the situation during the general recession.
Bharat Wagon & Engg. Co. Ltd.(BWEL), Muzaffarpur Unit
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REHABILTATION OF WAGONS
We also have experts/engineers with extensive experience in ‘Rehabilitation and Modifications
of Wagons’ and can take up rehabilitation of ANY MAKE of railway freight wagons or
passenger coaches. We can assist your railways in transfer of technology and imparting training
for maintenance. To analyse and review the extent of rehabilitation requirement, we can send a
team of expert engineers to customers place. The team will work jointly with customers’
railways for assessment of the work involvement and spares requirement. By investing only one-
third of the cost of a new wagon, one gets back a life of round 10 years after the Rehabilitation.
(v) Product profile of the BWEL
At the present time, Bharat Wagon Engineering Company Limited is one of the subsidiary of
Bharat Bharti Udyog Limited which has other subsidiary has a good liaison away i.e.
(i) Burn standard company.
(ii) Praith Waite and company limited.
(iii) Bharat Process and Mechanical Engineering Limited.
(iv) Lagan Jute Machinery Company Limited.
At the present time Bharat Wagon and Engineering Company Limited has a target of an average
30 to 35 wagons per month.
It is producing Broad Gauge Freight Wagon. Wagon component pressing, castings and
fabrication works are being done here. Casting jobs-grey iron casting up to 12 tonnes capacity.
At Bela works, oil tanks, heavy girdens, Transmission Towers and other heavy fabrications
works are being done. But now it is closed.
The production and manufacturing chart of BWEL Muzaffarpur unit are:-
Rolling Stock : Fright Wagon (Open Type) – Box N
Fright Wagon (Covered Type) – MBC
Fright Wagon (Flat type) – BPN
Fright Wagon (Spl Purpose) –BWTA
Casting Jobs : Grey Iron Casting upto 10 tonnes capacity per piece.
Sugar Mill Machineries : Complete Rollers Reselling.
17. 17
Filters Press Cystallizers Sulphus.
Furnale Condenser Conveyor Mill
Looping Mollassess and Mama pumpete
Defenale Road Trailer : Defenale Tank Carrier
Trailer upto 20 MT Capacity
Coal Mining Equipment : Coal Tube Mine Cars Rope Way Bulket.
Screw Pile Bridness : Tailer made Bridns with all relevant component to suit the river breadth.
Steel Fabrication Work : Suitable for steel plants. Thermal power plants, Oil Installation,
Fertilizer units Railroads, Bridge structure.
Transmission Towers and sub-stations structure :
Manufacturing and exertion of transmission towers and sub-station structure.
Valuable Customer Wagon : Indian Railway, Ministry of Defence
Steel Fabrication :Road Construction Department, Irrigation Department, H.E.C., BCCL,
FCI, BHEL, Nagal Paper and Pumps Mill, Eastern Railway.
C.I. Casting : Sugar Mills of U.P., Bihar and Nepal, U.P. State Electricity Board,
Road Construction Department.
L.P.G. Cylinders : Indian Oil Corporation Ltd. Hindustan Petroleum Corp. Ltd.
Bharat Petroleum Corp. Ltd.
Pontoon Bridges : Naogachhia (Bhagalpur), Kataunjha, Runisaidpur, (Sitamarhi), Bihar Pool
Nirman Nigam, Patna (Bihar)
At present Bharat Wagon is only manufacturing rolling stock. In other words, We can tell that
the Production of rolling stock is & rest everything has been stopped.
18. 18
SELLING WITH INDIAN RAILWAY
Over the years the company has built a broad customer base in almost all product categories. The
primary customer for wagons is the Indian Railways and about 98% of the revenue in this area of
BWEL’s business accrues from purchase of freight wagons by the Indian Railways. The
important customers for the different products are as follows:
Product Important Customers (Procurement)
Railway Wagons The Indian Railways
Ministry of Defence
Casting Jobs Sugar Mills in Uttar Pradesh, Bihar and Nepal
Uttar Pradesh State Electricity Board
Road Construction Department, Govt. of Bihar
Steel Fabrications Road Construction Department, Govt. of Bihar
Irrigation Department, Govt. of India
Heavy Engineering Corporation, Ranchi
BCCL- Western Coal Fields
Railway and Road Bridge Structural
FCI, Barauni
Rampur Engineering Works
Bihar State Electricity Board
Nagaland Paper & Pulp Mills
Eastern Railways
LPG ylinders and Fuel Storage
Tanks
Indian Oil Corporation Ltd, Hpcl and Bharat Petroleum
Corporation Ltd.
The principal customers by value are the Indian Railways, the predominant customer, Bihar
Rajya Pul Nirman Nigam Limited, Numaligarh Refinery Limited, Bihar State Electricity Board
and Oil Companies like IOCL, BOCL and HPCL.
The order book position as on 1st
September 2001 is given below:
Product Order Book
Wagons Physical Order for FWU: 705
Order Value (Rs. Lakh): Rs.3666
New Wagon Order Value (Rs. Lakh): Rs. 111.13
Total Order Book Rs. 3777.13 Lakh
Raw materials in wagon manufacturing can be broadly divided into two categories:
(a) DM components, being components, which are inspected by the RDSO before they are
supplied to us and
19. 19
(b) Non-DM components, being low value components, which are the procured locally and do
not require RDSO inspection.
Common DM components include steel, bogies, coupler sets, air brake equipment, air brake
pipe, wheelsets, slack adjuster, nylon bush, door check spring, bearing, twist lock, draw gear
(quick draw) and draw bar.
Principal raw materials for our mining machines are flat steel products, such as steel plates. We
normally source our entire requirement from suppliers such as SAIL and TISCO. We also
require high tensile steel plates, which are sourced from dealers of major companies in India or
abroad. We require forgings and castings, which we normally source from locally available
forging manufacturers in addition to manufacturing casting at our in-house foundry. We have an
arrangement with komatsu Mining Germany (Demag) for supply of components and spares
required for heavy earth moving and mining equipment. We import components such as
hydraulics and gear boxes for our heavy earth moving mining equipment from komatsu Mining
Germany, Rexroth, Carraro and also several other reputed companies in India and abroad. We
source our requirements of cylinders and engines for our machines from indigenous sources.
In the Railway Budget for 2008-09, it was announced that Indian Railway will procure around
20,000 wagons. In addition to demand from Indian Railways, demand for wagons from public
sector companies such as National Aluminum Company Limited (?NALCO?), National Thermal
Power Corporation Limited (?NTPC?), Container Corporation of India Limited (?CONCR?), etc.
has also been picking up. Companies such as NALCO, NTPC, etc. Procure wagons for their in-
house utilization where as CONCOR procures container flats for container transportation
purposes. The demand of wagons has further been bolstered by the wagon Investment Scheme
(?WIS?), which was implemented by Indian Railway wef April 1, 2005.
Wheel sets are one of the most critical components in wagon manufacturing and the approximate
cost of wheel sets as a percentage of the total selling price of wagon for non Indian Railway
customers is almost 30-35%. The prices of wheel sets, are significantly dependent on prices in
the international market and their global demand and supply situation. To manage the cyclical
fluctuations in the prices of wheelsets, we have developed relationship with a number of RDSO
approved vendors in countries such as China, Spain, Brazil and Switzerland. We placed order
with such vendors, based on our outstanding order book position and based on the delivery
requirements of our customers. Due to significant price fluctuation of wheelsets in the global
markets and current global shortage, we endeavour that our non-Indian Railway customers?
Open letters of credit against our purchase orders with our approved vendors directly. In order to
reduce the risk of price fluctuation of wheelsets and to ensure continuous supply of wheelsets for
our production, we are planning to setup an axle machining and wheelset assembly plant at an
estimated cost of Rs 129.33 mn. The assembly plant will have an assembly capacity of 10,000-
12,000 wheelsets per annum. We believe an axle machining and wheelset assembly shop would
20. 20
give us a cost advantage with respect to savings in freight charges and would also give us greater
operational continuity.
Non-DM components such as horizontal levers and safety plates, being low value components,
are procured locally and require no RDSO inspection. Suppliers of Non-DM components are
approved as per guidelines specified in our quality assurance manual and in accordance with the
requirements.
Railway Rolling Stocks, Components & Track Materials
BWEL is the largest Rolling Stock manufacturer in India. With an annual production capacity of
over 8600 Vehicular Units, BSCL offers the following range of Railway Wagons.
Open Type Freight Wagons for transportation of Coal, Ores, Minerals etc.
Closed Type Freight Wagons for transportation of all classes of General Goods, Food Grains,
Bagged Cement etc.
Bottom Discharge Open Ballast Hopper Wagon with automatic unloading facility (suitable for
bulk goods)
Special Leak Proof Wagon for Alumina & Cement (with pneumatic discharge system direct from
wagon to the unloading point)
Milk Tank Wagon
Special Wagon for Liquefied Petroleum Gas (LPG)
Flat Wagon for Transportation of steels.
Crop Wagon for Transportation of scraps.
BSCL’s foundry practice dates to the 18th
century and today with its modernised Steel Plant,
Moulding Equipment, Electric Arc Furnaces, Heat-treatment and Shot Blasting facilities, the
annual production of 15,000 MT covers finished Alloy Steel Castings, Heavy Nihard and Mn
Steel Casting and Crossing. Maximum weight of castings that can be made is 4 MT.
The battery of Drop Stamping Hammers and Hydraulic Presses with supporting machinery’s
including heavy die machining facilities have enabled the Forge Division to produce customer
need based forging and pressings.
Maximum dimensions – 450/R Bloom.
Maximum weight – Drop Stamping: 40 Kg,
Plain Forging: 2.5 Tons
21. 21
Starting from the raw mining to the finished product BSCL,s Refractory Unit offers a one
window solution for a wide range of products basic bricks e.g. Mag. Chrome, Chrome Mag,
Magnetite, Chemically Bonded (Unburnt), Direct Bonded, Mag. Carbon, Refractories for
Copper, Cement & Glass and many other Varieties.
BSCL is the “preferred supplier” for Steel Structurals for major Rail and Road Bridges in India.
Supplies have included structural work for bridges over India’s widest Rivers: Ganga, Krishna,
Godavari, Hooghly and Bramhaputra to name a few.
Steel Frame Building Structures
Steel Plant Structural Work
Steel Plant Equipment
FACILITY PROVIDED BY INDIAN RAILWAY
New Delhi During 2009-10, the Indian Railway plan to acquire 18,000 new wagons against
11,000 in 2008-09. Announcing this in Parliament today, the Minister of Railways, Mamata
Banerjee, said that there was a growing demand for wagons in Indian Railways.
The ministry also proposes to take over the wagon units of Burn Standard Co. Ltd. (BSCL) and
Braithwaite & Co. Ltd. (BCL), under the Ministry of Heavy Industries. During the year 2008-09,
the Government released Rs 8-38 crore to BSCL, Rs 3.76 crore to BCL for modernization and
production facilities.
During 2008-09, BSCL has registered a net loss of 199.92 crore INR (Prov.) and a loss of 151-29
crore INR during 2007-08 (Actual). During 2008-09, BC has registered a net profit of 1.42 crore
INR (Prov.) and a profit of 0.55 crore INR during 2007-08 (Actual).
The proposal to acquire 18,000 new wagon is good news for the domestic wagon manufacturing
firms.
VRS Natarajan, CMD, BEML felt that the budget was very encouraging and would increase the
business of coach builders and manufacturers.
The minister also proposed premium freight service for container movement with assured transit
time and a mega logistic hub alongside eastern and western dedicated freight corridors.
22. 22
MARKETING OF RAW MATERIAL
The wagon manufacturers are not unduly worried over supply of raw materials such as steel and
wheels by the Railways. Some of the wagon manufacturers express their reservation about the
Railways plans to acquire the wagon units of Burn Standards and to set up a new coach factory
in Kanchrapara (West Bengal).
The two wagon units of Burn Standards employ about 1,000 people – 700 in Burnpur Factory
and 300 in Howrah factory. Together the units produce about 1,000 wagons a year. In 2008-
2009, the company posted a cash profit of a little over Rs 5 crore (unaudited) on a turnover of
about Rs 175 crore, of which the share of the wagon units will be about Rs 80 crore.
Meanwhile, Mr. Pawan K. Rui, Chairman, Jessop & Company, in a statement said, Jessop being
a manufacture of EMU coaches for several years would not only welcome the proposed an EMU
coach factory at Kanchrapara but would also be keen to share the experience in this regard.
More than 60 par cent jump in the wagon procurement target would also a boon to Jessop, now
ready with improved designs of wagons and aluminium wagons. According to Mr Umesh
Choudhary, Managing Director, Titagarh Wagons, the dedicated railway freight corridor project
would be a game changer for the logistics industry and the economy.
The project’s emphasis on light-weight specialized wagons is important for Titagarh Wagons set
to enter the manufacture of aluminium wagons manufacturing.”
Titagarh Wagons, in collaboration with Freightcar America, is designing a prototype for
aluminium wagons in the country. It is expected to be ready by December.
In case of EMU coaches, the company has bagged its first set of orders for six rakes from the
Railways and expects order flow to increase in view of the Minister’s proposal to increase
frequency of local and short-distance EMU trains.
After the heightened expectations in the run up to the Railway Budget, the announcements made
on Friday may have come as a dampener. With no roll back of the increase in freight charges, the
Budget did not provide much of an impetus, on the lines expected by Corporate India. But it does
spell positively on companies associated in the business of making railway related goods.
Companies such as BEML, Texmaco and Titagarh Wagons that are in the business of making
wagons, EMU and metro coaches stand to benefit from the announced addition of 18,000
wagons (as against 11,000 in FY09) to Indian Railways fleet in the current year.
The announcement of new train services, refurbishment of older coaches and the intended
introduction of high-capacity air-conditioned double-decker trains will also bode well for these
wagon manufactures. The setting up of a new coach factory for manufacturing 500 coaches a
year in Kanchrapara in West Bengal may not pose significant competition to the players as the
23. 23
Railways (according to industry estimates) is expected to acquire 1,00,000 wagon units in the
11th
Five year Plan.
Such a high wagon procurement target may result in all the players getting meaty orders.
That the planned investment outlay by the Railways has been increased to Rs 40,745 crore is also
a positive for other railway-related stocks. The budget has increased its allocation (compared
with the one made in the interim budget) for new lines from Rs 1,100 crore to Rs 2,921 crore.
In addition, even though the budget did not spell out definitive plans for taking the dedicated
freight corridors forward, that the Ministry continues to focus on it also reflects well for these
container operators. Players such as Concor and Gateway distriparks, give their cold chain
initiatives may also benefit from the proposed development of cold storage facilities for farmers
to store vegetables and fruits.
24. 24
ORGANIZATIONAL STRUCTURE
Bharat Wagon and Engineering Company Limited is divided into following department :-
(i) Personnel Department - The personnel department is hereby in charged (Personel and
Administration) assistant who is also looking after the job of welfare officer.
(ii) Finance Department – Finance department is headed by a Manager (finance). The work
of finance department is to fix the price of the product by costing methods and other allied works
related to the employees for which they are entitled.
(iii) Stores and Purchase Department - Stores and purchase department is headed by Material
Manager. The department conducts the supplies and purchase of all materials and products. This
department receives the order for the supply of products.
(iv) Work Department – Work department is headed by Deputy Manager (Works). The main
function is to take care about wagon assembly, cutting and welding, Pross and smithy, machine
shop, finishing and painting shop.
(v) Planning and Civil Department – Deputy Manager (planning and inspection) headed this
department. The main function of the department is to get the civil work done and capital
budgets etc.
The structure at Bharat Wagon and Engineering Limited Company is shown in adjacent page :-
26. 26
FUNCTIONS OF VARIOUS DEPARTMENT AT BWEL
PERSONNEL DEPARTMENT
Employment Administration :-
Cultivation of specific sources of manpower.
Selection process including test, interview, examination etc.
Placement, induction.
Maintenance of employees records.
Transfer, promotion, demotion, disciplinary action, grievances etc.
Manpower planning.
Wages rates clearance allowance and other monetary allowances.
Cost of living incise.
Administration of employees appraisal plan.
INDUSTRIAL RELATIONS :-
Settlement of grievances.
Negotiation and dealing with trade union and labour department.
Interpretation and dissemination of company’s personnel policies.
Legal matters concerning employees.
Employment moral.
Communication
WELFARE ADMINISTRATION :-
Canteen and cafeteria
Workmen compensation.
Educational, recreational and cultural activities.
Co-operative activities.
Transport.
27. 27
Personnel guidance and counseling.
MANAGEMENT DEPARTMENT :-
To provide training facility to improve skills of the employees.
To facilitate them on the job training and off the job training.
Arranging seminars and conferences.
Providing educational and vocational counseling.
Execute the performance appraisal of the employees potential and capability.
MANPOWER PLAINNING :-
RECRUITMENT AND SELECTION
REPRESENTATION OF COMPANY IN LABOUR COURT
ISSUING CHARGE SHEET AND CONDUCTING DOMESTIC INQUIRY
FURNISHING VARIOUS STATUTORY RETURN TO HEAD-OFFICE AS WEL AS
DIFFERENT AGENCIES ETC.
LIASIONING WITH THE TRAINING OF AGENCIES :
MOTIVATING AND PRACTICAL TRAINING OF EMPLOYEE FOR PRODUCTIV.
2. Finance Department
The work of the finance department is to find the price of the product by costing method and
other allied workers related to the monetary payments of all sorts of the employees for which
they are entitled.
The main functions of finance department
a. Maintenance of books of accounts related to purchase sale, stores establishment and
salary v and wages payment etc.
b. Preparation and submission of various management reports on productions, cost control,
cash flow stock, sales etc.
c. Statutory compliance under excise, income tax, provident funds, E.S.I. etc.
d. Handling matters related to statutory internal C.A.G. commercial and tax audits.
28. 28
e. Analysis of accounting: data for decision-making purposes.
f. Financial concurrence to different proposal including capital investment decision.
g. Cash management and handling banking matters.
3. Works Production Department
1. Fabrication and assembling of railway goods.
2. Manufacturing of wagon components. Fabrication of component of railway bridges/ road
bridges.
Safety Officers have been appointed in this company to render the following function :-
a. To act as an expert and safety and pollution control.
b. To provide preventive measures against occupational diseases so as to product. The
health of the workers and promote better hygienic atmosphere through the co-operation of the
medical officers of the factory.
c. To implement the safety provisions under the factories act, 1948.
d. To ensure accident free atmosphere and to check operations and issue work permits after
the hazards having removed and repair made.
e. To check from time to time water and air pollution.
f. To check noise hazards through appropriate means and to reduce them to the appropriate
means and to reduce them to the appropriate sound levels.
g. To prevent the loss of the property of the organization due to accidents and mishandling o
the tools and materials of the company.
h. To procure safety equipment and prepare for safety budgets and also to see that those
safety aids are properly utilized by the workmen.
(ix) To promote safety education and training for th workmen and also motivate them through
safety campaign and rewards.
(x) To make safety amidst, appraisal and review to ensure against recurrence of accidents.
(xi) To laise with the Factory Inspector as and recognized training institute like Central
Labour Institutes (CLI), Regional Labour Institutes (RLI).
29. 29
(xii) To prepare accident reports and analysis for submission to organize works department is
divided into different sections & sub sections for better and systematic production as follows:-
Department / Sections Department Code No.
Personnel 200
Canteen 203
Store 401
Loading 403
Press and Smithy 501
Cutting and Welding 502
Drilling 503
Wagon Assembly 504
Wagon Finishing 505
Foundary 506
Machine-shop 507
Sub-Assembly/Shot Blast 508
Progress 509
Template 510
Inspection 511
Mechanical and Electrical Maintenance 512
Safety 516
4. Maintenance Department
The Function of the maintenance Dept. is as follow:
Mechanical Maintenance of all machineries and equipments.
Electrical maintenance of all machineries and equipments.
Vehicle maintenance.
Generator operations and maintenance.
Erection and commissioning of equipments.
5. Planning and Inspection Department:
The main functions of Planning and Inspection Department are:-
Total planning of the unit in respect of the requirements of materials for wagon production.
Liaison with railways and other officers for better output in the line of demand.
30. 30
Inspection of all incoming material for wagon production and other items.
Audit check of different stages of production of as per the manufacturing standards of railway
C-72 for better quality assurance and do the satisfaction of RDSO (Railway design & standard
organization).
Liaison with mounting team for mounting of wheel set.
Security Department
The main functions of the Security Department are
To supervise the factory from any pilferage, damage, fire hazards as well as security of plant &
machineries.
To maintain the records of incoming and outgoing materials, persons etc.
Medical Section
B.W.E.L., Muzaffarpur having a full fledged medical provide first aid to the employees.
8. Computer Science
This department is completely meant for Management Information system (MIS) and co-
ordination with all the concerned departments and render the following functions.
(a) To keep proper records of employees, their identification no. and relevant details.
(b) To keep records of accounts of production.
(c) To maintain the database management of the company to coordinate with all the
departments in keeping information up to date.
(d) To make pay – roll of the employees.
(e) To keep records of accounts of production.
(f) To assist the finance department in preparing the balance sheet, sundry debtors, cash
Bank, GV. (General Voucher) etc.
(g) To prepare Goods Receipts Note (GRN), B.H.W.R. (Bolt, Nut, Washer & Riveties)
Bought out components, Issue, Vouchers etc. records for stores department.
(h) To prepare data entry of variable earning & deduction (monthly overtime, attendance,
31. 31
leave etc.
(i) To prepare monthly D.O. value position
9. Material Department
Material Department of Bharat Wagon & Engineering Company Limited, Muzaffarpur is very
important as it is primarily intended to assist in the production, maintenance and other allied
function of all departments in respect of
To make available balance flow of raw materials components, equipments and other materials
necessary to meet operational requirements.
To provide maintenance of materials, spare parts and general stores as required.
Material Department has been sub divided into major sections.
Purchase section is mainly engaged for procurement of all materials required for the company’s
business e.g. from paper pin to C.S. Bogie from calculator to shot blasting equipment.
Store section is mainly to engaged for receiving, storing issuance with all case of inventory
control and plays a vital role to achieve the targeted production with all possibilities of cost
reductions and make the company in profit. As because Bharat Wagon and Engineering
Company Limited is an engineering company and where the cost of raw materials for production
is 50-60% of the total cost incurred.
The unit wise manpower break-up is given below:
Unit As on 31st
March 2001 As on 1st
September
2001
Muzzafarpur Unit 771 743
Mokama Unit 741 707
Bela Works 110 101
Head office, Patna 105 113
Regional office, Kolkata 16 12
Regional office, New Delhi 06 06
Total 1749 1682
Strength and Opportunity Analysis
32. 32
Strengths
Established brand name
ISO-9002 certified factories for wagon
manufacturing
Location well connected by rail & road
Ample space available for future expansion
at Mokamah & Bela
Skilled workforce with rich experience in
steel erection & fabrication
Good track record
Opportunities
Moving into value added wagons-
Increase thrust in the area of pontoon Bridges
and Screw pile bridges
Focusing on oil companies for building
overhead/underground fuel storage tanks.
Utilisation of the excess space in the units at
Mokamah and Bela for expansion
Tapping export market for wagons
INDUSTRIAL MARKETING POLICIES
Powers are delegated to various agencies namely Board, Managing Director, General Managers
and other Officers depending upon the nature of issue. Some of the important Policies delegated
are mentioned below –
Board:
Policy matters relating to service conditions, wages and salary structures including allowances,
bonus, retirement benefits, not requiring Government’s approval.
Contracts (above rupees one crore). Write of bad Debts ( over Rs. 25000/-), Sanctioning above
20% excess over senctioned estimate in a project/item.
Ex-gratia payment above Rs. 10000/- in case of death / injury of company employees.
Appointment of officer above Dy. Manager
Manager post, scale- Rs. 5400-225-6300-250-9050/- (1995 Revision), and below Board Level.
Norms set by the BWEL for discharge of its functions:
The company has well defined procedures and guidelines for discharge of various functions.
These are highlighted below –
Manuals
33. 33
BWEL has procedural manuals covering important activities viz Purchase Manual, Works
Manual. These manuals ensure carrying of activities in a systematic and standardised manner and
eliminate the scope of exercise of discretion. While discharging the functions covered by these
manuals, the employees follow the provisions of these manuals.
Guidelines of Department of Public Enterprises
BWEL being a public Sector Enterprise follows the guidelines of Department of Oublic
Enterprises and directives of Government of India issued from time to time.
Burn standard Co Ltd
Braithwaite & Co Ltd
Bharat Wagon & Engg Co Ltd
The group companies have supplied various types of wagons with different capacities, both in
eight wheeler (Bogie type) and four wheelers to Indian Railways and many overseas Railways.
The group companies have also received ISO 9002 Certificates for manufacturing Wagons and
wagon components.
Railway Wagons Type of wagon manufactured:
Open Type Freight Wagon (BOXN)
Covered Type Freight Wagon (BCNA)
Flat Type Freight Wagon (BRNA)
Casting Jobs Grey Iron Casting including wagon components, bevel
gear box, screws and other components.
Sugar Mill machineries Complete Rollers, Roller Reshelling, Filter press,
Crystallizers, Sulphur furnance, Condensers, Conveyor
Mill Coupling, Molasses pumps and other allied
equipment.
Steel Fabrications Fabrications suitable for the following:
Steel Plants
Thermal Power plants
Oil Installations
Fertilizer Units
34. 34
Railway and Road Bridge Structural
Screw Pile Bridge Designing and manufacture of components for screw pile
bridges with all relevant components to suit river width.
Coal Minning Equipment Coal Tubs, Mine Cars, Ropeway Buckets
LPG Cylinders Manufacturing LPG Cylinder for domestic use
Projects Defence Road Trailers, Transmission Towers and Sub-
Station Structural
Product Range With Description
Product Category Description
Railway Freight
Wagons
BOXN – 8 Wheeler Broad Gauge Bogie Open Type Wagons fitted
with Cast Steel Casnub Bogies, High Tensile Centre Buffer Couplers
(NT) with single air brake system, Tare Wt. 22.47 MT,Pay Load –
58.81 MT and Gross Load – 81.28 MT.
BRNA – 8 Wheeler Broad Gauge Flat Wagons with fixed ends but
fitted with single air brake, Casnub bogies and HT CBC coupler
BCNA – 8 Wheeler Broad Gauge Bogie covered wagons fitted with
cast Steel Casnub Bogie with Air Brake and CNC(NT) couplers
Structural MS Trough plates – 8 mm thick MS double troughs used in screw
pile road bridges of width 0.76 m, length 4.27 m and 10 mm thick
double steel trough used in railway tracks on bridges.
Fender plates – 8 mm thick fender plates used in screw pile briges.
35. 35
Underground Mild Steel Tanks – 15KL, 20 KL, 45 KL and 70 KL
tanks
Grinders – Grinders for screw pile bridges
Wagon Components – Forged, Pressed and Fabricated components
for various types of wagons.
CI Castings Wagon Components, Bevel Gear Box, Standard plates & Various
components
Sugar Mill Items Rollers – New rollers and Reshelling of rollers
Tail Bar Couplings
Scraper Plates and Sulphur Burner
Machine Parts for Jute Mills
Other Miscellaneous
Items
Heavy Media Sump
Hopper used in coal washery units.
Coal tubs and Mines car
High Pressure Heat Exchanger Pipe for oil refinery
Coal handling plant equipment for power plant
I.D. Fan impeller
I.D. and F.D. fan shafts
Crush shafts
Steel Brake Drum
List of Major Plant & machineries for production of wagons at Muzaffarpur
S.No. Description Capacity Nos.
1. Brake Press M/C 315 T 1
2. Brake Press M/C 135 T 1`
3. Hyd. Press m/c 400 MT 2
36. 36
4. Hyd. Press m/c 250 MT 1
5. Profile gas Cutting m/c pug 1/8” to 6” thk 6
Straightline gas
6. Cutting m/c 50 MM thk 7
7. Profile Kangaroo gas cutting 38 mm thk 1
8. Pillar Drilling M/C 40 MM & 50 MM dia 2
9. Radial Drilling M/C 50 MM to 65 MM dia 5
10. Girder Drilling m/c 52 mm to 56 mm dia 1
11. Shearing m/c 10 mm to 16 mm thk 4
12. 3-Roll plate bending m/c 16 x 2500 mm 1
13. Power hammer (pneumatic) 5 cwt 2
14. Rivetting hammer 5 cwt 1
15. Cropping Machine up to isa150 x 150 x 12 2
16. Co2 mig welding m/c 450 amp 7
17. Welding transformer 450 amp 60
18. Welding transformer 350 amp 10
19. Submerged auto welding set 750 amp 2
20. Shaper Stroke-24” 2
21. Universal Milling M/c 400 x 1650 mm 2
22. Central Lathe 1.5 to 2 m centre dist & SP 2
bore 53 to 80 mm
23. Central Lathe SW-370 to 390 mm 2
24. Engine Lathe SW-870 mm 1
25. Turret Lathe SW-550 mm 1
26. Capstan Lathe SW-450 mm 1
37. 37
27. Horizontal Beam bending m/c 315 mt 1
28. Power Hacksaw 18” 1
29. Circular Sawing m/c Round 9” dia, SQ-8” 2
30. EOT Crane 5 T 5
31. EOT Crane 10 T 2
32. EOT Crane 15 T 3
33. Mobile Crane 10 T 1
34. Vacuum Tester 41 CFT / MM 1
35. Wagon Weighment machine 40 T 3
36. Platform Weighing Machine 30 T 1
37. Oil Fired Heating Furnace - 1
38. Power Winch 5, 10 T 2
39. Shot Blasting Plant 3-4 wagons 1
Machineries for Utility service
1. D.G. Set 250 KVA 4
2. D.G. Set 500 KVA 1
3. Air Compressor 400 CFM at 100 PSI 1
4. Air Compressor 535 CFM at 100 PSI 1
5. Air Compressor 547 CFM at 8 ATM(G) 1
6. Mobile Air Compressor 400 CFM 1
7. Fork Lifter 3 Ton 3
List of major plant and machineries in respect of structural fabrication
Sr.no. Description Capacity Nos.
1. Three roll bending m/c 16 x 2500 mm 1
38. 38
2. Shearing m/c 10 mm to 16 mm 4
3. CROPPING M/C IP TO ISA 150 X 150 X 12
4. PUG STRAIGHT LINE 50 MM THIK 7
CURRING M/C
5. PROFILE GAS 1/8 TO 6 THK 6
6. CUTTING M/C
7. PILLAR DRILLING 40 MM & 50 MM dia 2
M/C
8. Radial drilling m/c 50 mm to 63 mm dia 5
9. Brake press m/c 315 T 1
10. Ecentric press m/c 135 T 1
11. Shaper m/c stroke-24 2
12. Co2 mig welding m/c 450 amp 7
13. Welding transformer 450 amp 60
14. Power hacksaw 18 1
15. Centre lathe sw 370-390 mm 2
16. Mobile crane 10 t 1
17. Air Compressor 400 cfm at 100 psi 3
18. D.g. set 250 kva, 500 kva 5
19. Fork lifter 3 t 2
20. Mobile air compressor 400 cfm 2
21. Circular sawing Machine 9 dia & 8 SQ 1
22. Power winch 5, 10 t 2
39. 39
S. No. Description Capacity Nos.
1. Power source
a. Step down transformer 500 KVA 2(11kv-440 v)
2. Capacity power source
(a) Diesel Generator 250 Kva 1
(b) Diesel Generator 500 Kva 2
(c) Diesel Generator 20 Kva 1
3. Air compressor
Compressor (elect) 240 CFM 3
Compressor (elect) 565 CFM 1
Portable Compressor (diesel) 400 CFM 2
4. Cranes & Hoist
(a) EOT Crane 15 T 2
(b) EOT Crane 12 T 1
(c) EOT Crane 10 T 2
(d) Hot Crane 10 T 2
(e) Hot Crane 5 T 2
(f) Jib Crane 2 T 2
(g) Jib Crane 1 T 1
5. Mobile Cranes & Materials Handling Equipment
(a) MOBILE CRANE 7.5 T 1
(b) MOBILE CRANE 8 T 2
40. 40
(c) MOBILE CRANE 10 T 1
(d) FORK LIFTER 2.5 T 1
(e) LOCO PULSER (WAGON - 2
SHUNTER)
(f) DIESEL LORRY TRUCK 10 T 2
6. Shearing/Cropping/Punching/Shaw machines
A Shearing Machine 10 mm x 2500 mm 1
B Shearing Machine 16 mm x 2500 mm 1
C Shearing Machine 7mm x 3200 mm 1
D Cropping Machine angle upto 150x150X10 1
E Cropping Machine angle upto 150x150X10 1
F Punching Machine upto 7/16” thickness 1
G Circular saw machine upto 150 mm 1
H Power Hackshaw upto 150 mm 1
a) Profile Cutting machines 1.5 m x 150 mm thk 3
b) Profile cutting machines 1.5mx3.0mx150mm thk 1
c) Pug Straogjt edge cutting m/c 50 mm thk 3
7. Power Press & Hammers
a) Hydraulic Press 250 mt 2
b) Pillar type hydraulic press 600 T/400 T 2
c) Ecentric Electro mech. Press 80 T 1
d) Pneumatic Hammer 400, 250, 200 & 100 kg 4
41. 41
e) Pneumatic Chipping Hammer 10 mm x 180 mm 5
8. Power Press & Hammers
a) Hydraulic press 250 MT 2
b) Pillar Type Hydraulic Press 600 T/400 T 2
c) Eccentric Electro mech. Press 80 T 1
d) Pneumatic Hammer 400, 250, 200 & 100 kg 4
e) Pneumatic Chipping Hammer 10 mm x 180 mm 5
9. Welding Equipment
a) Arc welding transformer 400/450 38
b) Mig/Mag Welding Machine 400 A 9
c) Submerged Arc Welding Machine 600 A 1
10. penumatic rivetting hammer upto 20/22 mm 14
11. machine/drills
A Heavy Duty Lathe cht 500 mm x 5.5 m bl 2
B Heavy Duty Lathe cht 350 mm x 4.6 m bl 1
C Centre Lathe cht 125 mm x 2.0 m bl 3
D Centre Lathe cht 200 mm x 1.5 m bl 1
E Capstan Lathe collet dia 40 mm x350 m 2
F Shaper Double Arm Stroke 26” 1
G Shaper Single Arm Stroke 20” 1
H Planer Heavy Duty bed 3 x 1.5 m, HT 1.2 M 1
42. 42
I Planer Light Duty bed 1/45 x 0.5 m, HT 0.45 M 1
J Slotter Heavy Duty Stroke 500 mm bed dia 1 m 1
K Plain Milling Machine -
L Universal Milling Machine bed 1.25m, ht 0.4 m 1
M Boring Machine (Horizontal) d 1.0 m x 12 m 1
N Boring m/c (Vertical) double Head900mm od*500 mm id*2M10Lg 2
O Shell Boring m/c double head Sugar Mill roller Boring 2
P Gang Drilling m/c double head 1.25” , BL 13 M 1
Q Universal Drilling m/c size 1.5” 1
R Radial Drilling Machine size 1/25”/1.5”/2” 3
S Surface Grinding m/c 8” x 5.5” x 2” 1
T Pedestal Grinding m/c 16” x 5” x 1.5” 1
U Pedestal Grinding m/c 18” x 2.5” x 2.5” 1
V Portable Drilling m/c 20 M 2
12. foundry equipment
a) Cupola 5t. 2t 3
b) Oil Fire Melting Furnace 0.5 t 1
c) Hot Metal Ladles 8t, 4t, 2t 1
d) Coal fired Core Drying Oven 250-300 degree c 2
e) Sand Muller Machine 5 cft/hrs 1
f) Jolt Squeeze Moulding Machine 340 kg 1
g) Wood Planner Machine 18” Cutter Length 1
h) Band Saw Machine 5 hp 1
13. Air Brake Testing Rig 6 kg/CM.SQ 2
14. Vacuum Brake testing machine -
43. 43
15. wagon weighment machine 40 T 2
16. Shot Blasting Plant 3-4 wagon/day 1
17. Power winches 15 hp 2
18. Three Roller Type Plate Bending m/c 16 mm tjocl x 2500 mm wide 1
Technical Parameters of Meter Gauge Coach for Indian and Vietnam Railways
Description Indian Railways Vietnam Railways
Track Gauge 1000 mm 1000 mm
Length over Bodyend Pannel 19500 mm 19000 mm
Length over Centre Buffer Couplers 20184 mm 20184 mm
Distance between Bogie Centres 13715 mm 13300 mm
Bogie Wheel Base 1980 mm 1980 mm
Max. Load per Axle 10 Te 10 Te
Width over Bodyside Pannel 2740 mm 2740 mm
Height of Roof from Rail Level
under Tare Condition
3355 mm 3700 mm
Height of Centre Buffer Coupler
from Rail under Tare Condition
825 mm 825 mm
Max. Service Speed 90 Kmph 100 Kmph
Wheel Dia. On Tread 952 mm 780 mm
Brake system Vacuum/Air Brake Air Brake
Max. Radius of Curvature 90 m 90 m
Coupler Type High Tensile C.B.C type
of IR Standard
High Tensile C.B.C type
AAR 10 A Contour
44. 44
PRESS & SMITHY SHOP
In this press and smithy shop there are seven open nearth furnances where coal burns on the
bed. On these famous various of parts are heated. The heated part is kept on the anvil with the
help of hammer the required shape is formed. In this shop more than 50 components are :-
Head Stock pressing
Anchor plate pressing
Anchor support pressing
Foot Step
Pull Road
Head Stock
Hand Wheel
Bolster
List & Numbering of machine :-
1. Hydraulic Press (400 T) -----
2. Hydraulic Press (250 T) -----
3. Press Machine (600 T) -----
4. Power Hammer (400 Kg) -----
5. Power Hammer (250 Kg) -----
6. Power Hammer (100 Kg) -----
7. Power Hammer (80 Kg) -----
8. Coal Fired Forge -----
9. Oil Fired Furnance -----
10. Blower -----
(1) Press & Press Work :-
The press is metal forming machine tool designed to shape of cut metal tool by applying
mechanical force or pressure. The metal is formed the desired shape without removal of clops.
45. 45
The presses are exclusively intended for mass production work and they present the fastest and
most efficient way to form a sheet metal in a finishing products.
(2) Power Press
The constructional feather of a power press is almost similar to the hand press the only difference
being, the ram instead of driven by hand is drives by power. The power press may be designated
as mechanical or hydraulic according to the type of working mechanism used to transmit power
to the ram. In a mechanical press, the rotary motion obtain from an electric motor is converted
into reverted into reciprocating movement of the ram by using different mechanical device. In a
hydraulic press, the fluid under high pressure is pumped on one side of the piston and then on the
other in a hydraulic cylinder to derive the reciprocating movement. A power press has driven by
crank and connecting road mechanism. The working of the press is similar to that of a hand
press. The punch is fitted on the end of the die is attached on the bolster plate. The fly wheel
mounted at the crank shaft stores up sheet metal is pressed between the punch and the die.
Power Press Parts :-
The different parts of a power press are described below :-
Base
Frame
Bolster Plate
Ram or slide
Pitman
Crank shaft or eccentric
Fly Wheel
Clutch
Brake
1. Base :-The base is the supporting member of the press and provides arrangement for
tilting and clamping the frame in an inclined press.
2. Frame :-All presses except the straight side type have “C” shaped frame to take up the
vertical thrust of the ram.
3. Bolster Plate :-The Bolster plate is a flat plate fetted on the base for supporting the die
block and other accessories of the press.
46. 46
4. Ram :-The ram is the reciprocating member of the press that slides with in the press and
guides and supports the punch at its bottom end.
5. Pitman :-The pitman is the connecting rod in a crank or eccentric driven press. The
position of the stroke of the ram can be changed by altering the length of the connecting rod.
6. Crank shaft of eccentric :-The rotary movement of the motor is motor is converted into
the reciprocating movement of the ram by crank and connecting rod, eccentric and connecting
rod, or many other mechanisms.
7. Fly Wheel :-The fly wheel is mounted at the end of the driving shaft and is connected to
it through clutch. The energy is stored up in the flywheel during idle periods and it is expand to
maintain the constant sped of the ram when the punch is pressed into the work. The fly wheel is
directly coupled with the electric motor.
8. Clutch :-The clutch is used for connecting and disconnecting the driving shaft with the
fly wheel when it is necessary to start or stop the movement of the ram.
9. Brake :-
The brakes are used to stop the movement of the driving shaft immediately after it is
disconnected from the fly wheel.
Hydraulic Press :-The hydraulic press is used to manufacture anchor plate. For this plate in the
oil furnance. The heated plates is kept horizontally on the machine table and ram is allowed to
press the plate due to downward movement the U-shaped anchor plate is manufactured.
The specification of this machine is as :-
Nominal Pressure ----- 250 Tons
Working Pressure ----- 200 atms.
Speed ----- 0.20 m/Sec.
Pressure exerted by Slide ----- 80 Tons
Stroke of slide ----- 500 mm
Maximum distance in table & slide ----- 630 mm
PNEUMATIC HAMMER :-On this machine the part which is to be manufactured is kept on
the after heating on the furnance and the ram is allowed to strike the component on the die. Due
to the strike of ram the component takes the shape that of the die. The machines have following
specifications :-
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Falling weight of ram ----- 400 Kg.
Maximum stroke of ram ----- 700 mm.
No. of blows per minute ----- 130 blows/mln.
Working Space ----- 530 mm.
Distance from centre of ram to housing ----- 520 mm.
Hydraulic press
48. 48
CUTTING AND WELDING SHOP
Introduction :-
This shop works under the Supervision of Mr. Taukir Ahmad this is one of the shops in which
the basic work is performed. As the name indicates this shop is mainly involved in cutting the
plates of different thickness in the desired shape & size and in the profile cutting.
In the metal-working work pieces of most difference shapes and dimensions and of different
materials are worked. The various working processes fall into the two groups, the of non-cutting
shaping, e.g. forging pressing, drawing, etc. and that of cutting shaping by which finish surface
of desired shape and dimensions is obtained by separating a layer from the parent work piece in
the form of chips e.g. turning, drilling milling etc.
List of no. of machine :-
1. Shearing Machine ---- 1
2. Cropping Shearing Machine ---- 2
3. Chipping Machine ---- 1
4. Profile Cutting Machine ---- 3
5. Kangaroo Machine ---- 1
Shearing Machine :-On the shearing machine the to be cut should be flat & the thickness should
not be more than 8 min. For cutting the flat plate is kept on the bed of the held of crane. The
machine consists of a cutting blade & no. of pressing bolts press the plate and keep it rigidly
fixed the downward movement of the cutting plate.
Cropping Machine :-On the cropping machine number of works are performed. This machine
can cut the flat plate of small sizes, angles, plates, square hollow rod & circular hollow rod. Also
this machine can be used as punching machine.
Chipping Machine :-This machine is use to produce an inclined shaped at end of plate which is
necessary in the end to end welding. This machine has a gun through which high pressure air
comes. This machine holds a chisel. The high-pressure air pushes the chisel. Which causes to cut
the plate?
Profile Cutting Machine :-This machine consists of a vertical column and two horizontal arms.
The one arm consists of the template and another arm consists of the welding torch and the small
driving motor. This machine can cut the plate of thickness of 35 to 40 mm. Through the welding
torch acetylene and oxygen gas is supplied. This machine requires extra amount of oxygen gas.
So two oxygen pipes are connected to the torch. To cut the plate in the desired shape. The same
49. 49
shape template is fitted to the upper arm and the magnetic roller of the second i.e. lower arm is
toughed to the template. The driving motor drives the torch. The torch moves through the profile
of the template and plate cut in the desired shape.
Kangaroo Machine :-One another plate cutting machine in this shop is Kangaroo Machine. This
is the biggest cutting machine. This machine consists of two welding torch. The torch can move
in all the three coordinate axis i.e. X,Y and Z axis. This is fully electronic controlled machine.
This machine consists of an electronic sensor and a horizontal plate. The drawing of the required
shape is kept on the horizontal plate and the sensor moves through the black lines of the drawing
this machine can be moved manually. The amount of acetylene and oxygen gas can be controlled
with the knobs.
In the welding section mainly bolster and cross bars are manufactured.
The Process of metal cutting in which chip is formed is affected by a relative motion between the
work piece and the hard edge of a cutting tool held against the work piece. Such relative motion
is produced by a combination or rotary and translating movements either of the work piece or of
the cutting toll or of both. Depending of the nature of his relating motion, metal cutting
processors are called by names example :- Turning, Planning, Boring etc.
A cutting tool may be used for cutting apart, as with a knife, or for removing chips. Parts are
produced by removing metal mostly in the form of small chips.
Chips :-The form and dimension of a chip metal machining indicates the nature and quality of a
particular machining process but the types of chip formed in influenced by the properties of the
material cut and various cutting conditions.
In engineering manufacturer particularly in metal machining process hard brittle metals have a
very limited use, and dutile metals are mostly used.
Chips of ductile metals are removed by varying proportions of shear flow. This results in general
type of shapes.
1. The discontinuous or segmental form.
2. The continuous or ribbon type.
Discontinuous or Segmental Chip :-
It consists of elements fractured into fairly small pieces ahead of cutting tool. This type of chip is
obtained in machining most brittle materials such as cast iron bronze. These materials rupture
during plastic deformation and form chip as separate small pipes. As these chips are produced,
the cutting edge smoothes over the irregularities and a fairly good finish is obtained. Tool life is
50. 50
also reasonably good, and the power consumptions low. Discontinuous chip can also be formed
on some ductile metals only under certain conditions particularly at very low speeds and if the
coefficient of friction is low with ductile metals, however the surface finish is bad and the tool
life is short.
Conditions :- Ending to promote its formation brittle metals, greater depth of cut, low cutting
speed and small rake angle.
Continuous chip :- It consists of elements bonded firmly together without being fractured.
Under the best conditions ribbon of metal which, under the microscope shows no sings of tear or
discontinuous. The upper side of a continuous chip has a small notch while the lower side, which
slides over the tool face, is smooth and shiny. The continuous form is considered most desirable
for low friction at the tool- chip interface lower power consumption long tool life and good
surface finish.
Shearing machine
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DRILLING SHOP.
INTRODCUTION :-
The drilling machine is one of the most important machine tools in a workshop . As regards its
importance it is second only to the lathe. Although it was primarily designed to originate a hole,
it can perform a number of similar operations. In drilling machines holes may be drilled quickly
and at a low cost. The hole is generated by the rotating edge of a cutting tool known as the drill
which exerts a large force on the work clamped on the table. As the machine tool exerts vertical
pressure to originate a hole it is loosely called a “drill press”.
Holes were drilled by the Egyptians in 1200 B.C. about 3000 years ago by how drills. The bow
drill is the mother of the present day metal cutting drilling machine.
In the drilling shop there are different types of drilling machines such as radial drilling machine.
RADIAL DRILLIGN MACHINE :-The radial drilling machine is indented for drilling
medium to large and heavy work pieces. The machine consists of a heavy, round, vertical
coulomb mounted on a large base. The column supports a radial arm which can be raised and
lowered to accommodate work piece of different bights. The arm may be swung around to any
position over the work bed. The drill head containing mechanism for rotating and feeding the
drill is mounted on a radial arm and can be moved horizontally on the guide ways and clamped at
any desired position. These three movements in a radial drilling machine when combined
together permit the drill to be located at any desired point on large work piece for drilling the
hole. When several holes are drilled on a drilled on provide guide ways on which the drill head
may be made to slide. The arm may be swage bound the column. In some machine this
movement is controlled by separates motor.
Drill head :- The drill head mounted on the radial arm and drives the drill spindle . It encloses an
the mechanism for driving the drill at multiple speeds and at different feed. At the mechanisms
and control are may be made to slide on the guide ways of the arm for adjusting the position of
drill spindle with respect to the work. After the spindle has been properly adjusted in position the
drill head is clamped on the radial arm.
Universal Drilling Machine :- It is one of the important drilling machine. This drilling machine
can produce a hole any direction at any angle. The universal drilling machine consists of a
vertical i.e. horizontally, vertically and at any inclination. The drilling can be done by automatic
feed mechanism and by manual operation.
Semi Universal radial drilling machine :- It is same as universal radial drilling machine except
this drilling machine cannot produce a hole in inclined direction. This machine consists of two
electrical motors. One is used for the operation of drilling and the another is used for the vertical
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movement of horizontal arm is the feed. In these machine water is used as a coolant the chip
which comes out from the operation is continues chip.
Sensitive drilling machine :- On the machine small sized hole is drilled usually a drill of 5 mm
and 6 mm is used for the machine has a very long bed and a gang of three drilling machine. This
machine is used to produce a hole in the very long channel. For operation the channel is kept on
the bed the jig is fitted to the channel and with the help jig bush the hole is produced at desired
position.
Drilling of Job :- In the shop drilling is done by two methods, i.e. by marking and by jig. The
following are the drill size & which are used for drilling in this shop are 5 mm, 6 mm, 11 mm,
13.5mm 17.5mm 21.5 mm and 23.5 mm. These are the drill size which is used here for drilling
marking takes a lot of time and it requires more skilled person for marking . so drilling of
component by marking is used fro a few, components where it is different to set a jig. For mass
production of components jig is used for drilling. The thickness of the jig plate, which is in
practice, is 12 mm. To manufacture jig a hole greater die is done in the jig plate and bush of
required drill size is filled in the hole, The material of the jig bush is called IV and IS: 1875. In
this drilling shop there is one universal radial machine, two semi universal radial drilling
machine and a few ordinary machines. There is one gang drilling machine and one sensitive
drilling machine.
Universal radial drilling machine
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MACHINE SHOP
INTRODUCTION :-
The shop works under the supervision of Mr. S.B.P. Shirivastva . This is the biggest shop of this
organization . In this shop there are various type of machines. :-
Such as :-
1. Lathe - 11
2. Drilling M/c - 2
3. Shaper - 2
4. Slotter milling m/c grinder - 3
5. Planed - 2
6. Etc. - 2
The Lathe :-In the year 1797Henry Maudslay and Englishman, designed the first screw cutting
lathe which is forerun C of the present day.
Function of Lathe :- The main function of lathe is to remove metal from a piece off work to
give if the required shape and size. This is accomplished by holding the work securely and
rigidity an the machine and then remove metal from the work in the form of chips. To cut the
material properly the tool should be harder than the material of the work piece. Should be rigidly
help on the machine and should be fed or progressed in a definite way relative to the work.
Lathe Parts :
1. Bed
2. Head Stock
3. Tail Stock
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4. Carriage
5. Feed Mechanism
6. Screw Cutting Mechanism
Description and Foundation of Lathe Parts :-
1. The Bed :-The Lathe bed forms the machine . The head stock and tail stock are located at
either end of the bed and the carriage rest over the lathe bed and slides on it. The lathe bed being
the main guiding member of the tool for accurate machining work.
2. The head Stock :-The head stock is secured permanently on the inner ways at the left
hand end
of the lathe bed it provides mechanical of rotating the work at multiple speeds.
3. Tail Stock or Loose Headstock :-The tail stock is located on the inner ways at he right
hand end of the bed. This has two main uses.
(a) It supports the other end of the work when it is being machined between centrs.
(b) It hole a tool par per forming operations such as drilling remaining tapping etc.
4. Carriage :-
The carriage of a lathe has several parts that serve to support, move and control the
cutting. It consists of toll parts :-
(a) Saddle
(b) Cross-slide
(c) Compound slide or compound rest
(d) Tool past and
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(e) Apron.
5. Feed Mechanism :The movement of the tool relates to work is lumed as “feed” . A lathe
tool may have three types of the lathe axis; the movement is termed as longitudinal fed and is
effected by the movement of carriage.
6. HEAVY DUTY LATHE
The heavy duty lathe 4 jaws chuck and can hold a job of India .. can rotate up to a mix . Speed of
315 rpm.
The motor, which is required to rotate the chuck, has the following specification. This is 3 phase
induction motor and required 415 volts . It s dello connection the horsepower of the motor is 50
H.P. and the out put shaft of this motor can rotate speed of 1460 rpm. The tail stock of the lathe
consists of separate electric motor to move to move it self on the lathe bed.
HORIZENTAL BORING MACHINE
This machine is used for the boring purpose of big components. This machine is driven by
electric motor & with the help of gear mechanism and main shaft is rotated. The sail, which is to
be mechanized, is kept on the bed. Before it, a ring is inserted over the sail to rigidly damp it.
The main shaft consists of to heads, which has groove in which cutting tool is fitted & frightened
with the bolts. The cutting head starts cutting from opposite sides both the cutting tools rotate in
opposite direction.
SHAPPER MACHINE
This machine which is used here is known as Double sharper machine . As the name itself the
machine has two ram & one long table. Both ram on the table and as per the requirement on or
57. 57
both machine is used to produce good surface on rough work place. Also it can be used to cut a
key way & for many other operations too.
Centre lathe machine
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FOUNDARY SHOP
Mr. S.B.P. Srivastava supervises the work of this shop. This is also very important shop of this
plant. In this shop casting is done. The various parts on the wagon
are manufactured in this shop.This casting is divided into three groups Low & Medium casting
are again divided in to sub group Green and dry and loam casting of sweep moulding. For
moulding clay is mixed with send to improve binding strength. Normally Bentonite & cow dung
improved the porous nature of sand. Normally 3% clay is mixes with sand. For casting first
mould is prepared with help of moulding box.
As per the requirement core is used in moulding . Fro preparing core reinforcement is used
which supports. The pressure of the molten metal.
Green casting is used for mass production. For dry casting, the core and the prepared mould is
hearted from inside the coal oven to reduce the moisture & to improve the strength & reduce the
shrinkage allowance.
CUPOLA FURNACE :-This is very important type furnace. It has the bottom bed & air
chamber. During operation the bottom bed is closed & the inclined sand bed is prepared on the
bottom bed. The air chamber which is connected with the outlet of bower which supplies air to
the coke is 12 to 36 inches above the air chambers. Improve the firing . The coke is fired air
blown. As the coke produce heat nearly equal to 22000
C the ferrous metal starts melting.
After melting the metal flows downward and get stored on the sand bed. Due to its high density
the coke starts flowing. As the slag starts flowing outside it is confirmed that the metal is in the
fully molten state condition the gate is opened and the molten metal is allowed , to blow in the
59. 59
ladle. In this system the hot air which tends to pass from top is recycled and again supplied to
the air chamber. This reduces the cost of production.
ZONES CUPOLA:-The Cupola furnace is divided in various Zones. A number of chemical
reactions take place in this Zone, which are as follow as :-
1. Well :-It is the space between the bottom of tuyers and the sand bed. The metals are
trickles down after melting and collects in this space before it is tapped out.
2. Combustion Zone :-It is also known oxidizing zone. It is located between top of the
tuyers and theoretical level above it. The actual combustion takes place in this zone. More heat is
evolved due to silicon & manganese. A Temperature about 15400
C to 18700
C is produced. The
exothermic reaction taking place in this zone.
C+O2 ……………………………. CO2 – Heat
Si+O2 ……………………………. SiO2 – Heat
2 Mn + O2 ………………………… 2MnO2 + Heat
3. Reducing zone:-It is also known as productive zone. It is located between the top of the
combustion zone and the top lave of the coke bed. Co is reduced in co in this zone through an
endothermic reaction, as a result of which the temperature falls from combustion zone.
Temperature is about 12000
C of this zone.
CO2 – C (of coke) ……………………. 2CO + HEAT
60. 60
4. Melting zone :-The first layer of metal charge above the coke bed. This solid metal changes
to state in this zone.
3 Fe + 2 CO ---------------------------------- Fe3C + Co2
5. Preheating Zone :-It extends from above the melting zone to the bottom level of the charging
door and contains a number of alternate layers of coke and metal charges. The function of this
zone is to about 1093 C before the downward to enter the melting zone. This preheating takes
place due to the upward advancing hot gasses.
6. Stack Zone :-The empty portion of cupola the preheating zone. Which provides the passage
to hot gasses to go to atmosphere ,is known as stack zone.
Cupola Efficiency :- The thermal efficiency of cupola is given by the ratio of heat actually
utilized in melting zone and superheating the metal to the involved in through various means.
The ratio can mathematically :-
Percent Cupola :- Heat utilize in melting and super heating x 100
Calerific value of coke – heat involved due to
oxidation of iron , si and Mn
61. 61
WAGON ASSEMBLY SHOP
In this shop the various components which are manufactured in the different shops are assembled
and the completed and then set to the finishing shop. First of the assembly of wagon, the centre
sill is kept on the fixture.
Centre Sill -This is manufactured in the sub assembly shop. To manufacture two Z channels are
welder after welding the supporting plate is welded to require position and then it is sent for
marking . After marking drilling is done by the air gun. Lastly it is checked whether it is true
size or not. If not the length is reduced by gas cutting.
The length of the centre sill should be 9784 mm and width should 2960 mm. The centre sill is
placed in the fixture and cross bar bolster welder to it. After welding these two seal are attached
and is welder.
Now this knows “Under frame”, now riveting is done . The head stock also welded to the centre
still at the ends. The gusset plate and the cross bottom plate is welded to bolster and cross bar
respectively . The stranger welded to the under frame through out the length. The under frame is
placed on the manipulator for welding at the bottom side. Now the air brake cylinder and the
pipe line is fitted and clamped . The side body and end body is attached and riverted and welded
to the frame . This complete box is kept on the wheel .
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FINISHING SHOP
After assembling the wagon is sent to the finishing shop. In this the wagon is brought to the shot
blaster chamber. In this chamber small iron particle is allowed to strike on the wagon to remove
the extra welding deposit and the rust formed on it. The high pressure air helps the iron particle
to come out from the gun and to strike rapidly. In this chamber the working condition are very
hazardous. So the worker wears oxygen mask before doing work inside the chamber. After this
the wagon is painted and the specification are written on the wagon is painted and the
specifications are written on the wagon and then dispatched to Indian railway.
10. SUPPLIER OF MAIN WAGON COMPONENTS
Components Suppliers
1. Wheel W.A.P. Banglore
2. Bogie BESCO Kolkata
3. High Tension Couler H.D.C. Kolkata
4. Air Brake Equipment 1. Escort Ltd. Faridabad
2. Stone India Ltd. Delhi
3. Bharat Braks & Value Ltd. Kolkata
5. Steel 1. Bokaro Steel Plant
6. Bearign 2. Tisco Indi Thmken India Jamshedpur
65. 65
TEMPLATE SHOP
Before describing the template t is worth while to elaborate the word “template”. This is a
pattern or gauge a time in mass scale. This saves a lot of time, as no marking is necessary when
using template . Basically templates are of two types :
1. Marking Template
2. Checking Template
The main objective of this shop is making templates of all the consigned wagon components
where a certain profile cutting is necessary.
The manufacturing of template is done with the help of the design and drawing provided by
R.D.S.O. Lucknow . Also the allowances for different tools are taken into consideration during
marketing the template. The varies machine to machine. The templates here are usually made of
mild steel . They are of small thicknesses.Working in this shop needs greatest accuracy because
shapes all the components made with the help of template depends upon the template. Thus a
minor fault cans a great fault in the production.
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SCRAP :MEANING AND DEFINATION
Scrap has various definitions and meaning in different contexts. Broadly scrap is materials.
Discarded from manufacturing operations that may be suitable for re processing. Scrap is a term
used to describe the recycling of metal. Old unwanted metal such as left out iron sheets, building
supplies, surplus materials, useless equipment, safety appliances, wornout tools machine part etc.
Sometimes some raw material which is basically to be used for some special purpose but on due
inspection it is observed that material does not meet required specifications, or is of of poor
quality and is not suitable for the purpose, such material is also considered as scrap. Scrap is
material that has been found to be unfit for further processing. Here in BWEL muzaffarpur
various type of scrap is produced . Broadly various types of scrap produced in BWEL
muzaffarpur can be classified as follows:
1. scrap from wagons shop :
Left out metal sheets after cutting out of required shapes of sheets used in production of
LHB FIAT wagons.
Sheet portions left out after cutting by laser cutting machine.
Iron pieces and bits that are of not suitable to be welded with wagons frame.
Metal fillings and residue left out during machining of LHB wagons.
2. Scrap from shell shop :
Left out metal sheets during cutting out upper and side frames.
3. Scrap from sheet metal shop :
Damaged or mutilated iron or steel sheet which are not suitable for further use.
4. Scrap from furnishing shops :
Various types unused material like foams, leather, unused wooden parts etc…
5. Miscellaneous scrap :
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Wooden scrap from carpentry shop.
Empty paint BOXES AND TUBES.
68. 68
LIST OF SCRAP MATERIALS PRODUCED IN BWEL
MUZAFFARPUR
1. punching, sheet cutting etc of various sizes. shapes and thickness, etc.
2. scrap of ms skeleton and its cuttings of varous sizes. shapes and thickness upto 10 mm.
3. scraps of cuttings of ms plate skeleton, bar, rods, strips etcof various sizes. shapes and
thickness.
4. scrap of ms plate skeleton and its cuttings of various sizes. shapes and thickness 10 mm
and above (cutting allowed for loading purpose only)
5. scrap of pcv insulated copper cable and wire of different sizes, shapes, thickness and
length including leads of welding torcheswith or without attachements.
6. scrap of empty iron drums cap 200 kg released from bitumen compound broken/unbroken
with or without lid and residue.
7. misc. scrap of ms and cr consisting of cuttings, punchings, angels, channels, circles, fine
melting and other small manufacturing scrap of shop, scrapped window blanks etc of
various sizes, shapes and thickness etc. aluminium scrap consisting of sheet cuttings,
skeleton cuttings, off cuts cuttings, punchings, angels, channels, mouldings, extrusions,
pipes, conduit, chequred sheet cuttings, rejected and condemned components of
aluminium, etc.
8. aluminum scrap consisting of sheet cuttings skelton cuttings, off cuts, cuttings,
punchings, angels, channels,moulding extrusions, pipes, conduit, chequred sheet cuttings,
rejected and condemned components of aluminum, etc.
9. scrap of cr off cut and its cuttings of various sizes, shapes and thickness upto 4 mm. scrap
of cr skelton carline type and its cuttings of sizes, shapes and thickness upto 4 mm.
10. scrap of cr off cuts and its cuttings of various sizes, shapes and thickness mainly 4-6 mm
including chequred plate off cuts.
11. scrap of cr skelteon and its cuttings of various sizes, shapes and thickness 4 to 6 mm.
12. scrap of pvc flooring off cuts of various sizes, shapes, grades and shades with or without
glue etc.
13. scrap of used and condemned ferrous spare parts of various types of machines, vehicles,
eot cranes etc. like silencer flexible connection, torque convector, clutch plates, brake
shoes, connecting rod, gear leaver, axle shaft, the rod, fan blades, shockers, cylinder
69. 69
head, roller, chain, hub, master cylinder, roller bearings, eot crane wheels, diplory wheels
etc. and other ferrous scrap of spare parts with or without non ferrous attachements.
14. scrap of ms and cr rejected and condemned wagon components released during
manufacturing like cantrail, sole bar, side frame, end extension etc, cuttings, angels,
channels.
15. scrap of ms skeleton and its cuttings of various sizes. shapes and thickness upto 10 mm.
16. scrap off cr off cut and its cuttings of various sizes, shapes and thickness upto 4mm. misc
scrap of stainless steel of various grades mainly ferretic and consisting of sheet cuttings,
skeleton cuttings, off cuts, angles, channels, cuttings, punching moldings, shop made
rejected wagon components and other manufacturing scrap of various types, grades and
shapes. scrap of cr skeleton and its cuttings of various sizes.
shapes and thickness upto 4 mm.
17. scrap of cr slitting trim cut end waste in coil shape of various sizes, width upto 65 mm.
18. scrap of ms skeleton and its cuttings of various sizes. shapes and thickness upto 10 mm.
19. scrap of ms skeleton and its cuttings of various sizes. shapes and thickness upto 10 mm
and above.
20. scrap of cr skeleton and its cuttings of various sizes. shapes and thickness upto 4 mm.
21. scrap of cr trim cut end waste slitting in coil shape max. width upto 140 mm and
thickness upto 6 mm.
22. scrap of ms off cuts and its cuttings of various sizes. shapes and thickness mainly 6 mm
and above and width mainly upto 200 mm including chequred plate off cuts if any.
23. scrap of stainless steel trim cut end waste slitting in shape of various grades mainly non
ferratic, and of various shapes, sizes, thickness etc. misc mixed scrap of ms and cr
consisting of angels, channels, small off cuts, sheet cuts rejected and condemned small
wagon components cuttings, manufacturing scrap, molding, pipes, square tubes, mesh
etc.
24. scrap of codemnned floor griding machines with or without accessories.
25. scrap of limpet/nftc sheet cuttings of various sizes and grades and shades.
26. scrap of limpet/nftc sheet cuttings of various sizes, shapes, thickness, grades and shades.
27. scrap of lp sheet (sunmica) of various shapes, sizes, and thickness with or without pasting
of plywood including kachra type small strips etc.
70. 70
28. scrap of wooden sleepers cut pieces of different shape & sizes.
29. scrap of rejected & condemned stainless steel water tank modules with or without ferrous
attachments etc.(9 nos)
30. scrap of limpet/nftc sheet cuttings of various sizes, shapes, thickness, grades and shades
etc.
31. scrap of condemned fire extnguishers of foam types.
71. 71
SCRAP MANAGEMENT AND IMPORTANCE
Such a large quantity of scrap needs a proper way of management and disposal.
Otherwise it would create wastage and environmental hazards.
The proper utilization, processing, disposal and other type of related maintainance of
various types of scraps is broadly termed as scrap management.
Scrap management process differs from industry to industry. Scrap from large and big
industry usually serves as raw materials for small scale industries and factories .
In case of small industries like in case iron or sheet metal industry scrap management
simply consists of activity in which scrap material is taken from workshop to a scrap
yard, where they are processed for later melting into new products.
But in case of a large industry where different types of raw material is used and different
processes and operations are carried out a very comprehensive method of scrap
management is necessary for the betterment of industry.
Thus we see that scrap management plays an indispensable role in upliftment of the
industry. Now we are going discuss the scrap management in context of BWEL
MUZAFFARPUR.
SCRAP MANAGEMENT IN BWEL MUZAFFARPUR
Scrap production in BWEL MUZAFFARPUR is one of largest in the North India. Every
year crores of scrap is produced in various workshops of BWEL MUZAFFARPUR,
whose proper management and disposal is very necessary. That’s why scrap Management
is very important aspect in proper functioning of BWEL MUZAFFARPUR.
Specially for this purpose there is a scrap depot in the factory campus where all the scrap
and waste material is dumped and whole process of scrap management is carried out from
there.
Various poles and bins are designated and number for arranging different types of scrap.
Different type of scrap is distributed at different places in scrap yard according to the
requirement and auction requirement.
Dy. CMM of scrap Depot is incharge of all the proceedings carried out related to scrap in
the factory.
Now the management of scrap starts right from the workshops.
In each and every workshop scrap bins are suitably placed where different types of scrap
is placed. This scrap is before hand distributed according to its type, such that there is no
need of differentiating scrap after it reaches the scrap depot. These bins are actually large
containers which can be suitably installed on truck.
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A large crane picks up these containers and puts it upon the trucks which carries these
scrap upto the scrap depot and unload them in the scrap depot according to the designated
place.
These places are actually designated according to the pole number or heap number.
Now there is form known as Advise Note on which all the paper work related to the
transportation of scrap from the workshop to the scrap depot takes place.
Person concerned in workshop fills the advice note and sends it along with the scrap to
the scrap depot. In scrap depot the concerned official receives the scrap truck and further
fills the advice note.
Pole number or heap number where scrap is unlocated is noted down. Advise note is kept
in records.
The size of scrap heap in depot is kept, keeping in mind various factors.
When the amoumt of scrap is large enough auction of this scrap is done.
Before auction various beforehead preparation are done.
Size of scrap heap is kept such that it is easier for the trader to carry the scrap easily. If
the scrap heap is smaller it will be easier for the trader or the dealer carried to desired
position, moreover less scrap heap means less weight and less transportation costs for the
trader and he will be more encouraged to buy the scrap.
Certain minimum price is selected beforehand by the depot officials by reviewing the
present market prices of iron and other such kind of scrap.
Sometime special scrap such scrap of Mynmar wagons, include the taxes also. Various
traders or dealers are informed beforehand by various means.
A special catalogue of scrap available is distributed among these traders and dealers.
This catalogue tells aqbout the different types of scraps available, their weight, minimum
piece before auction and position where they are placed in the scrap depot.
These traders are either from some small scale industries or just moderators who further
sell these scrap to other people.
The highest bidder or particular scrap gets to have that scrap.
This scraps serves as raw materials for these small factories.
Some scrap such that of iron and other metallic scrap is often remelted and cast into other
useful products. Other miscellaneous scrap such as tubes, plastic, etc are also useful for
some small scale.
73. 73
VARIOUS LOCATIONS FOR SCRAP IN SCRAP DEPOT
In scrap Depot large amount of scrap is to placed in distributed manner so that it is easy
to distinguish various types of scrap and other information related with it.
For this purpose scrap depot following type of division are done :
A) Sectors
B) Poles
C) Bins
Sectors: These are the broad classification of a certain area that has certain amount and
certain type of scrap lying there. These are alphabetically numbered. There are sectors
numbered from sector A to sector H in scrap depot.
Poles: There are many poles which are numerically numbered. Below these poles heaps
and lots of scrap are placed.
Bins: These are cemented scrap bines where whole of scrap is dumped. These again are
numbered.
All of these are simply identification to know where and what type of scrap is placed in
the scrap depot.
In the catalogue also it is given that so much kg of scrap placed in given secto or near the
given pole or in certain beam.
This also helps the bidders and purchasers during the auction to easily and properly
identify and inspect the scrap.
74. 74
TERMS AND CONDITIONS OF AUCTION SALE OF SCRAP IN
BWEL MUZAFFARPUR
1. ENTRY :
Its welcome for participating in auction to all bidders who accept and abide by the terms
and conditions of auction sale given here under.
All bidders intending to participate in the auction shall be charged Rs 15/- each as
entrance fee which is non returnable and every participating bidder has to submit a
demand draft of Rs 10,000/- each in favour of FA and COAO/BWEL/MFZ payable at
New Delhi issued by any nationalized bank which ahall be normally returned after the
auction is over.
Any bidder who has deposited demand draft of Rs 10,000/- as entry fee can participate in
the bidding. If it found at any stage that bidder has not deposited the entry fees, then the
bids of such a bidder may be cancelled.
The lots put up for auction, can be inspected at any working day prior to the auction.
The bidder can enter the scrap yard one hour before the commencement of the auction.
The intended bidders who wish to participate in the auction should bring authority letters
on letter pad of the firm with name and address to whom he represents.
They should produce Trade license ST/CST/No. on their letterhead to participate in the
auction at the Depot gate before commencement of the auction, the demand draft and a
copy of letter shall be kept at gate and receipt will be issued to them.
Participants taking part in the auction have to mention reference of Sales Tax
Registration No. if there is any, at the time of entrance to the auction.
2. BIDDING:
It must be clearly understood by the bidder that auction document have been issued to
bim and he is permitted to bid in consideration of his agreement to the condition here in
after.
The highest bid given by the bidder for a particular lot will irrevocable till final decision
by the auction conducting officer.
The quantity declared against each lot/item is approximate. Mere acceptance of bid by the
auction conducting officer and deposition of the cost by the purchaser shall not transfer
the property in goods to purchaser unless the lot/item is weighed, measured or tested as
the case may be warrant by the Depot Officer incharge of material on production of
delivery cost.
In event of any dispute arising out of or relating any bid, the item/lot in respect of which
the dispute arises shall be immediately put up for sale against the last undisputed bidding.
